Ravinder Tanwar

1

Operational control and cost reduction in
Crystalline Silicon Solar Cells and Modules
manufacturing

• Ravinder Tanwar
• Director Operations
• Websol Energy Systems Ltd
• Presented at
• Renewable Energy Chennai 2009 Conference

2
Websol Energy Systems Ltd

• Manufacturing Started in 1994
• Product Monocrystalline Solar Cells and
  Modules
• Capacity 42 MW
• Expansion 60MW by 2011 and 120 MW by 2012
• Exporting more than 95 of total cells and
  module production to Europe and USA

Websol Energy Systems Ltd
3
Total integrated Plant from Cells to Modules
Plant Capacity 120 MW
Websol Energy Systems Ltd
4
SEZ Falta Plant details

• Land Size 6.23 acres
• Capacity -120 MW cells and Modules
• Land Acquired - Nov 2006
• Plant operational in May -2009

Websol Energy Systems Ltd
5
Focus areas for next 5 years

• Develop cost effective technology through
  collaborate research
• For improvement in cell efficiency .
• Achieve production target of 120MW by 2012
• Forward integration in Solar PV power plants in
  domestic and international market
• Increase market share through setting up
  manufacturing base and develop new market for
  existing products

Websol Energy Systems Ltd
6
Stages in Value Chain of Crystalline Silicon
Solar PV System
Websol presence
Websol Energy Systems Ltd
Valuation of Project
7
Websol efforts in operational control and Cost
reduction in manufacturing
Wafer
Module
PV Cell

• Operation control
• Increase yield in manufacturing and reduce
  chemicals and paste in manufacturing ,
• Automation in manufacturing
• Efficiency
• Increase cell efficiency from 10 to 17 through
  improvement in Surface passivation , control in
  printing parameters ,texturization and diffusion
  parameters
• Economies of scale
• Production increase from 1MW to 42 MW
• 120 MWp photovoltaic Cell and module facility
  built up at Falta ,West Bengal
• Technologies
• Develop process and system to work with 180
  Micron wafers
• Performance
• Solar power grid connected and standalone systems
  are working excellently from last 15 years
• Integration
• Integration in manufacturing from cells to power
  plant ensure total control on supply chain Long
  contract for supply of wafers

Valuation of Project
8
Cost reduction potential in Silicon Crystalline
Solar Systems
Cost mentioned above are subjected to change as
per price of silicon and raw material cost
Websol Energy Systems Ltd
9
Factor driving cost reduction

• Polysilicon price 300 to less than 100
• Wire sawing now lt 0.25 per watt
• Large wafers 3inch to 6 inch
• Thinner wafer 300 micron to 180 micron
• Manufacturing capacity 1MW to 100 MW
• Increase automation in silicon to module
  manufacturing
• Improve manufacturing process
• Manufacturing Yield
• Factors which have made impact in cost reduction
  
• Cell efficiency
• Thinner wafers
• Solar grade wafer

Websol Energy Systems Ltd
Valuation of Project
10
Increase in efficiency in cell

• 2 point improvement in cell efficiency from 16
  to 18 will lower the cost per watt of entire
  solar supply change by roughly by 10

• Improve silicon usage /watt
• Reduction panel material per watt
• Reduction installation labour cost/watt

Websol Energy Systems Ltd
Valuation of Project
11
Module Cost Verses Cell Efficiency
Websol Energy Systems Ltd
12
Module Cost Verses Polysi Cost
Module
Wafer
Websol Energy Systems Ltd
13

• Thank you for Kind attention

Websol Energy Systems Ltd